Historically, the development cycle for both defense and civilian radar infrastructure has been long, requiring significant time, innovation, and capital investment. Defense applications have traditionally driven radar advancements, but these systems often come at a high cost while delivering improved performance. As a result, there has been a shift from traditional mechanically controlled radar systems to active electronically scanned arrays (AESA), which leverage advanced multi-beam capabilities to enhance accuracy in both time and space. The versatility of AESA is equally impressive, enabling the integration of multiple radar systems onto a single platform, as illustrated in Figure 1.
Figure 1: Active phased array structure supports electronic beam steering and combines multiple radars into one system.
These operational advantages make AESA a strong candidate to replace traditional defense radar systems. Already widely used in military applications, AESA technology enhances sensor networks and improves situational awareness on modern battlefields. In civil applications, it has the potential to significantly impact public safety. A single, multifunctional AESA radar network can improve air traffic control and bring substantial economic benefits to the country while supporting national defense. Meteorologists can better predict severe weather, saving lives, and AESA sensors help integrate unmanned vehicles into mainstream society, potentially transforming transportation and commerce.
However, transitioning AESA from military to civilian and commercial use still presents challenges. Relying on outdated RF components and assembly methods hinders progress. To understand where this research is heading, it's essential to look at its origins and current development path.
1. R&D Roadmap
The next generation of active antenna technology originated from research projects in the 1960s. With the advancement of GaAs monolithic microwave integrated circuits (MMIC) in the 1980s, AESA development accelerated. DARPA partnered with companies like MACOM to advance microwave/millimeter wave MMIC and microwave analog front-end technology (MAFET). These efforts moved advanced hybrid semiconductor tech from labs to commercial production, leading to the first few watts of MMIC. Further developments in semiconductors and packaging enabled the use of RF modules in mainstream PCB and surface mount technologies. Post-DARPA, the focus was on higher power, efficiency, and frequency. Gallium nitride (GaN) became a key player due to its high frequency, reliability, and consistency.
In 2014, DARPA launched the ACT program to apply commercial best practices to shorten the development and manufacturing cycles of next-gen radar, EW, and communication systems. The goal is to create digital interconnected phased array components that allow larger systems without full redesigns. This approach aims to reduce time-to-market and costs, making AESA more viable for civil and commercial use.
2. Slat Array vs. Tile Array
The cost and feasibility of AESA depend largely on its electronics and how they're assembled. T/R modules account for about half the cost of a radar array, influenced by MMIC type, packaging, and substrate. Traditional T/R modules use ceramic substrates and "chip thin wire" assembly, which is expensive compared to commercial plastic-sealed MMICs. RF boards and cables also add to the cost. Slat arrays, which have slats perpendicular to the front, offer large areas for T/R modules and thermal management but require many RF boards and cables, increasing design complexity.
Tile arrays, however, offer a more compact design. They integrate antenna units and RF beamformers on a single board, reducing connections and cables. T/R modules are mounted directly on the back, using standard commercial packaging to lower costs. This design reduces the area of RF boards and significantly lowers overall system cost.
3. Multi-Function Radar
MACOM collaborated with MIT Lincoln Laboratory to optimize tile array structures and validate cost-effective manufacturing. The Multi-Function Phased Array Radar (MPAR) project, supported by FAA and NOAA, integrates eight traditional radar functions into one platform. The first MPAR uses scalable planar arrays (SSAR) to detect weather, aircraft, and air targets.
Unlike conventional mechanical systems, SPAR tile radar uses a fixed planar array with hundreds or thousands of T/R units. It includes a front-hole PCB with radiating elements and beamforming networks, with T/R modules mounted on the back via standard processes. A second PCB, the backplane, handles DC power and processing, connecting to the APCB via low-cost connectors. This modular design allows for easy upgrades and scalability.
The first MPAR prototype is being tested at NSSL in Oklahoma, improving weather forecasting and providing a foundation for future systems. For FAA, it enhances air traffic monitoring and homeland defense. MACOM has developed over 6,000 T/R modules, achieving an average noise figure of 3.7 dB, as shown in Figure 6.
4. Tile AESA Opportunities
With declining government spending on traditional radars, developing cost-effective new systems requires combining innovative RF architecture with commercial manufacturing. Tile AESA enables fast, affordable, and upgradable radar systems for defense, civil, and commercial use. Design techniques for tile arrays can be applied to communication and sensing, offering low-cost active antenna solutions for 5G, drones, and automotive radar.
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